Two part hot top



sept. 2s, 1965 Filed May 14, 1962 M. H. GATHMANN TWO PART HOT TOP 5 Sheets-Sheet l MMM/M INVENTOR MARK H.GATHMANN SBP- 28, 1965 M. H. GATHMANN 3,208,116

TWO PART HOT TOP Filed May 14, 1962 5 Sheets-Sheet 2 INVENTOR MARK H. GATHMANN oHornev Sept. 28, 1965 M. H. GATHMANN TWO PART HOT TOP 5 Sheets-Sheet 5 Filed May 14, 1962 INVENTOR MARK H. GTHMANN 'ZUM/(7% oTTorney Sept. 28, 1965 M. H. GATHMANN 3,208,116

TWO PART HOT TOP Filed May 14, 1962 5 Sheets-Sheet 4 /N VENTOR MA RK H. GA THMA /V/V By 9a/gv A Homey Sept. 28, 1965 M. H. GATHMANN 3,208,116

TWO PART HOT TOP Filed May 14, 1962 5 Sheets-Sheet 5 /Nl/E/VTO/P MA RK H. GA THMA/VN Alfa/nay United States Patent O 3,208,116 TWO PART HOT TOP Mark H. Gathmann, Chicago, Ill., assignor to United States Steel Corporation, a corporation of New Jersey Filed May 14, 1962, Ser. No. 196,031 Claims. (Cl. 22-200) This application which is a continuation-in-part of my copending application Serial No. 803,622 filed April 2, 1959, now abandoned, relates to a shrink head casing or hot top and to a method of making an ingot therewith. Many types of shrink head casing have been used, but they may be generally considered of the permanent or non-reusable types. In general the permanent type has a metal casing lined with a refractory material and a coating on the refractory material adjacent the metal being poured. The non-reusable type is generally made of fire clay. Shrink head casings in gene-ral use have various disadvantages. They may be expensive, a large shoulder may be formed on the ingot and it is impossible to efficiently cast different weights of ingots in the same size mold with the shrink head casing. The shrink head casings of which I have knowledge must all be assembled before being placed on the ingot mold. With the larger size molds in particular the weight of the assembled shrink head casing is great and it is very difficult to handle and place on the mold. In some instances the hot top may oat upward with the molten metal,` thus resulting in inefficient operation.

It is therefore an object of my invention to provide a shrink head casing which incorporates desirable features of both the permanent and non-reusable types.

Another object is to provide such a shrink head casing wherein the main portion is re-usable and the remaining portion is made separate therefrom and may be assembled therewith after the main portion is placed on the ingot mold.

Still another object is to provide such a shrink head casing which will produce a sound homogeneous ingot with a minimum of shoulder ledge on the ingot.

A further object is to provide such a easing which permits sound ingots of more `than one size to be cast in the same size ingot mold.

A still further object is to provide a method of casting a sound homogeneous metal ingot in which the percentage of usable metal is high.

Another object is to provide means for preventing the hot top from floating upwardly.

These and other objects will be more apparent after referring to the following specification and attached drawings, in which:

FIGURE 1 is a vertical section showing a shrink head assembly on an ingot mold;

FIGURE 2 is a view in section taken on the line II-II of FIGURE 1;

FIGURE 3 is a view, similar to FIGURE 1, showing a second embodiment of my invention;

FIGURE 4 is a top plan View of another embodiment of my invention;

FIGURE 5 is a sectional view taken on the line V-V of FIGURE 4;

FIGURE 6 is a sectional view of a detail of the shrink head of FIGURES 4 and 5;

FIGURE 7 is a view, similar to FIGURE 6, showing a slight modification;

FIGURE 8 is a View, similar to FIGURE 6, showing a further modification;

FIGURE 9 is a plan view of another embodiment of my invention for use with large molds;

FIGURE 10 is a view taken on the line X-X of FIG- URE 9;

FIGURE 11 is an enlarged view taken on the line XI--XI of FIGURE 9;

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FIGURE 12 is a view, similar to FIGURE l1, but showing a further modification; and

FIGURE 13 is a view showing a still further embodiment.

Referring more particularly to FIGURES 1 and 2 of the drawings, reference numeral 2 indicates a standard ingot mold having the usual vertical opening 4 therein. A metallic casing 6 having a generally vertical opening 8 therein is superimposed on the mold 2. The .opening 8 is slightly smaller than the opening 4 so that the casing 6 extends slightly over the opening 4 completely around its periphery. The casing 6 preferably is made `of cast iron with an opening 12 therein to increase its insulating value. A refractory liner 14 fits within the opening 8 with its lower end extending into the mold opening 4 and its top extending above the top of casing 6. A generally horizontal ange 16 is provided on top of the liner 14 and extends outwardly over the casing 6. The flange 16 may extend completely `around the liner or be in spaced apart sections. The lower end of the liner is rounded at 118. The refractory is preferably of low density so as to increase its insulating value. The .thickness of the liner is held to a minimum so as to provide a minimum of shoulder ledge on the ingot. For example, the liner may be two inches thick. Wood blocks 20 or other blocking mea-ns support the liner 14 on the casing 6, the blocks resting on top of the liner 6 and bearing against .the bottom :of the frame 16. Blocks 20 of different height may be used to vary the extension of the sleeve 14 in the opening.

For best results .the lower end of the liner 14 should extend at least 3 below the bottom of the metal casing. The hot metal is then poured into the mold until the top thereof is slightly above the bottom of the liner 14. It is preferred to momentarily stop or greatly reduce the flow of molten metal at this point so as to form a barrier and prevent leakage of hot metal from the mold. Flow of metal into the mold is then continued until the required volume has been poured. After the metal is poured into the mold 2 and refractory liner 14 the blocks 20 are removed so that the liner 14 is free to shrink and move downwardly with the solidifying ingot.

The embodiment of my invention shown in FIGURE 3 is generally the same as that shown in FIGURE 1 except for the construction of the refractory liner 22. In this embodiment the refractory liner 22 consists of a steel sleeve 24 having an outwardly extending horizontal ange 26 at its upper end and a bonded refractory 28 secured to the inner side of the sleeve 22. The bonded refractory 28 is preferably sand or other refractory material having a resin binder. The wood blocks 20 extend between the flange 26 and the top of the metal casing 6 in the same manner as in the first embodiment. The thickness of the sand and resin refractory may be as little as 1/2 inch. When the hot metal is poured into the mold 2 and n'ses in the liner 22 the portion of the refractory 28 contacted by the hot metal will form a powdered ash which will act as an insulator and also as a releasing agent between the ingot and casing 6, thus allowing the ingot to shrink properly in the mold without binding.

In the embodiment of my invention shown in FIGURES 4 to 6 a metallic casing 30 rests on top of the ingot mold 2. The metallic casing 30 has a generally vertical opening 32 therein which is slightly smaller than the opening 4 in the ingot mold so that the casing 30 extends slightly over the opening 4 completely around its periphery. The casing 3i) is provided with positioning or centering lugs 34 which fit over the wall of the ingot mold 2 on each side lof mold lugs 36 so as to prevent movement or shifting out of alignment of the casing 30 on the mold 2. The casing 30 is also provided with lifting lugs 38 at the top thereof. A refractory liner or sleeve 40, preferably of low density material, is inserted in opening 32 with its lower end extending into mold opening 4 and its top extending above the top of casing l30. Outwardly extending lugs or anges 42 are provided at the top of the casing 40. The casing 40 has a generally vertical opening 44 therein which is beveled or chamfered outwardly at its lower end 46. As in the first embodiment thickness of the refractory is held to a minimum so as to provide a minimum of shoulder ledge on the ingot. A metallic collar 48 is provided for the surface 46. As best shown in FIGURE 6 the collar 48 has a cylindrical upper portion 50 which tits into the main portion of the opening 44, a frusto-conical portion 52 extending downwardly therefrom in engagement with surface 46 and a lower portion 54 which extends across the bottom of the liner 40. The collar 48 may be attached to the liner 40 duringy formation yof the liner `or may be attached to the liner 40 by means of pins, not shown, extending through the collar 48 into the walls of the liner 40. The purpose of the collar 48 is to reduce refractory adhesion on the shoulder of the ingots and to alleviate breakage and falling of refractory particles into the ingot mold opening 4. Positioning blocks 56 are provided as in the other embodiments of my invention.

In FIGURE 7 a collar 58, similar to collar 48, has an outwardly extendining portion 60 which acts as a wiper strip.

In FIGURE 8 a collar 62, similar to collar 48, has a vertical ange 64 which further protects the refractory 40 from damage.

The sheet metal collars 48, 58 or 62 may also be used with the embodiment of my invention shown in FIGURES 1 and 2. Also when utilizing the sheet metal collar the sleeve 40 may be used without the metallic casing. In each of the embodiments a low density refractory lid may be placed on top of the metal in the shrink head casing if desired.

The embodiment of FIGURES 9 to 1l show my invention as applied to a large rectangular ingot mold 66; for example, a 118 inch high mold having an 84 inch by 39 inch opening 68 therein. These large molds are generally provided with trunnions 69 instead of lifting lugs. A cast metal casing 70 having a generally vertical opening 72 therein is superimposed on the mold 66. The opening 72 is slightly smaller than the opening 68 so that the casing 70 extends slightly over the opening 68 completely around its periphery. Outwardly and downwardly extending lugs 73 are arranged one on each side of the casing 70 so as to position the casing in correct position on mold 66. A refractory liner 74 is placed within the opening 72 after the metal casing 70 is placed on the top of the mold 66. The liner 74 is preferably made up of a plurality of flat slabs as shown so as to facilitate manufacture and handling without danger of breakage. The slabs have matching tongues 76 and 78 or other structure to hold the slabs in place at their ends, except at the four corners where miters 80 or other match cuts are provided. A metal strap 82 passes around the outside of the liner 74 so as to hold the slabs in assembled position. If desired more than one strap may be provided at different levels. Wood blocks 84 may be positioned under the strap 82 to hold the lining 74 in the desired vertical position to obtain the desired weight ingot.

As shown in FIGURE 12 some or all of the slabs may be provided with -outwardly extending lugs 86 for receiving wood or metal spacers 88 for positioning the liner 74 at the desired height. Ordinarily only one type of blocking arrangement will be used.

The casing 70 is provided with lifting lugs 90 and a U-shaped metal clip 92 having a slotted opening 94 therein is placed on top of the liner 74 in alignment with each lifting lug 90. A steel ring -or metal strap 96 is placed around each lifting lug 90 and is connected to the assocated clip 92 by means of Wire rope or steel strapping 98 provided with a turnbuckle or fastening clip 100 for adjustment purposes, the top part of the wire rope or strapping 98 being connected to the clip 92 by passing through the slot 94. Thus, the liner 74 is prevented from floating upwardly as the metal rises in it. It will be noted that the bottom of the liner 74 extends downwardly into the mold 66.

In making an ingot, molten steel is poured into the ingot mold 66 through the opening in liner 74 until the top of the metal is slightly above the bottom of the refractory liner 74. Flow of molten metal is then preferably stopped momentarily or the How greatly reduced so that metal will freeze between the opening 68 and the liner 74 and prevent leakage of metal from the ingot mold at this point. Flow of molten metal is then continued until it reaches the desired height in the liner 74. The spacer blocks 84 or 88 are then removed so that the liner 74 can oat downwardly with the cast metal as it shrinks.

An exothermic liner 102 is shown in FIGURE 13 which consists of a plate 104 with exothermic material 166 bonded thereto. This liner 102 may be used in any of the embodiments shown. The plate 104 acts as a backing material and other backing material, such as bonded sand, may be used in place thereof.

In each of the embodiments for -best ingot formation the mold top and the metal casing bottom should be machined, the diameter of the opening at the top of the mold should have a tolerance of plus 1/2 and minus zero from the designed dimensions, the diameter of the metal casing must have a minus tolerance of 1A" and the tolerance of the outside dimension of the sleeve should be minus 1A and plus 1/s.

While several embodiments of my invention have been shown and described, it will be apparent that other adaptations and modifications may be made without departing :from the scope of the following claims.

I claim:

1. The method of making a metal ingot comprising providing an ingot mold, placing a metal casing having a generally vertical opening therein in superimposed position on said mold, the vertical opening having a diameter less than the diameter of the opening in the ingot mold, then placing a liner having a length substantially greater than that of said metal casing within said metal casing with its lower end extending at least 3 below the bottom of said metal casing and the top thereof extending above the top of said metal casing, said liner having lugs at the top thereof, inserting a spacer member between the lugs and the top of said metal casing, then pouring molten metal into said mold and said liner to the desired height, and then removing the spacer members to permit the liner to move downwardly with the solidifying ingot.

2. The method of making a metal ingot comprising providing an ingot mold, placing a metal casing having a generally vertical opening therein in superimposed position on said mold, the vertical opening having a diameter less than the diameter of the opening in the ingot mold, then placing a refractory liner having a length substantially greater than that of said metal casing within said metal casing with its lower end extending at least 3 below the bottom of said metal casing and the top thereof extending above the top of said metal casing, said liner having lugs at the top thereof, inserting a spacer member between the lugs and the top of said metal casing, then pouring molten metal into said mold until the top thereof is slightly above the bottom of said refractroy liner, then momentarily stopping flow of molten metal into said mold, continuing flow of molten metal into said mold and into said refractory liner to the desired height, and then removing the spacer members to permit the liner to move downwardly With the solidifying ingot.

' 3. A shrink head casing for a mold having a generally vertical opening therein comprising a metallic casing the bottom of which is adapted to rest on top of said mold, said metallic casing having a generally vertical opening therein and lifting lugs on the outer surface thereof, a. preformed liner separate from and movable downwardly with respect to said casing and having a length substantially greater than that of said metallic casing, the top of the opening in said metallic casing being of such size as to permit insertion of said lining from the top of said casing, detachable means for supporting said liner within said metallic casing with the bottom thereof extending `below the bottom of said metallic casing and the top thereof extending above the top of said metallic casing, a U-shaped clip fitting over the top of said liner in line with at least some of said lifting lugs, and a exible member having one end secured to said clip and the other end secured to said lifting lug, said liner moving downwardly upon removal of said detachable support means.

4. The combination of a shrink head casing and a mold having a generally vertical opening therein, said shrink head casing comprising a metallic casing the bottom of which rests on top of said mold, said metallic casing having a generally vertical opening therein, the vertical opening of said casing having a diameter less than the diameter of the mold opening, a preformed liner separate from and movable downwardly with respect to said casing and having a length substantially greater than that of said metallic casing, the top of the opening in said metallic casing being of such size as to permit insertion of said lining from the top of said casing, and detachable means for supporting said liner within said metallic casing with the bottom thereof extending at least 3 in. below the bottom of said metallic casing and the top thereof extending above the top of said metallic casing, said liner moving downwardly upon removal of said detachable support means.

5. The combination of a shrink head casing and a mold having a Igenerally vertical Opening therein, said shrink head casing comprising a metallic casing the bottom of which rests on top of said mold, said metallic casing having a generally vertical opening therein, the vertical opening of said casing having a diameter less than the diameter of the mold opening, outwardly extending lugs on the bottom of said metallic casing adapted to engage said lugs on the mold, a preformed liner separate from and movable downwardly with respect to said casing and having a length substantially greater than that of said metallic casing, an outwardly extending horizontal flange on the top of said liner, the top of the opening in said metallic casing being of such size as to permit insertion of said liner from the top of said casing, and detachable means extending between the top of said metallic casing and the bottom of said horizontal flange for supporting said liner within said 4metallic casing with its lower end extending at least 3 in. below the bottom of the metallic casing in the mold opening, said liner moving downwardly upon removal of said detachable support means.

References Cited by the Examiner UNITED STATES PATENTS 1,235,166 7/17 Stewart et al 22-147 1,500,731 7/24 Howard et al. 22-147 1,689,174 `10/28 Perry 2-2-147 1,789,883 1/31 Roth 22-147 1,804,207 5/31 Charman et al 22-147 1,850,060 3/32 Harris 22-147 1,913,847 6/33 Messler 22-147 I1,921,730 8/33 Charman 22-147 2,263,437 11/41 Cameron 22-147 2,362,097 11/44 Rowe 22-147 2,668,336 2/54 Jones 22-147 2,867,871 1/59 Shepard 22-147 MARCUS U. LYONS, Primary Examiner.

MICHAEL V. BRINDISI, Examiner. 

1. THE METHOD OF MAKING A METAL INGOT COMPRISING PROVIDING AN INGOT MOLD, PLACING A METAL CASTING HAVING A GENERALLY VERTICAL OPENING THEREIN IN SUPERIMPOSED POSITION ON SAID MOLD, THE VERTICAL OPENING HAVING A DIAMETER LESS THAN THE DIAMETER OF THE OPENING IN THE INGOT MOLD, THEN PLACING A LINER HAVING A LENGTH SUBSTANTIALLY GREATER THAN THAT OF SAID METAL CASING WITHIN SAID METAL CASING WITH ITS LOWER END EXTENDING AT LEAST 3'''' BELOW THE BOTTOM OF SAID METAL CASING AND THE TOP THEREOF EXTENDING ABOVE THE TOP OF SAID METAL CASING, SAID LINER HAVING LUGS AT THE TOP THEREOF, INSERTING A SPACER MEMBER BETWEEN THE LUGS AND THE TOP OF SAID METAL CASING, THEN POURING MOLTEN METAL INTO SAID MOLD AND SAID LINER TO THE DESIRED HEIGHT, AND THEN REMOVING THE SPACER MEMBERS TO PERMIT THE LINER TO MOVE DOWNWARDLY WITH THE SOLIDIFYING INGOT. 